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6 Maintenance

Maintain the tank cleaning machine with care.
Read the instructions carefully and pay special attention to the warnings!
Always keep minor spare parts kit in stock.

6.1

General maintenance

Step 1

!

Always read the technical data thoroughly, see section 7 Technical data.

Recommended spare parts: Order service kits from the service kits list, see section 8 Parts list and service kits
Ordering spare parts: Contact your local Alfa Laval sales company.

6.2

General dismantling set up

NOTE

A rigorously implemented preventative maintenance program will significantly reduce repair costs over the life of the Alfa Laval
GJ.The foundation of such a program is regularly scheduled inspections to discover and replace worn or damaged parts before
they can cause the failure of other, more costly, components. The inspection intervals required will depend on the severity of the
application, but a complete internal inspection at 100 hours of operation is recommended initially.

Step 1
STORAGE
The Alfa Laval GJ should be washed out with clean water after
each use to remove any foreign material or soft substances left in
the machine that may harden during storage and cause the Alfa
Laval GJ to seize or lock up. A clean water rinse through the Alfa
Laval GJ will also wash out any residues of chemical cleaners or
recirculated wash water that could adversely affect the seals and
O-rings during prolonged contact in storage. The best position to
store the Alfa Laval GJ is to stand it up with the inlet connection
facing down.

Step 2
EXTERNAL INSPECTION INTERVALS
Before every shift, the stator (12) and the nozzles (16) should be
inspected for debris. Examine the stator (12) by loosening the
collar set screw (30), while holding on the flats of the cap (6) and
remove the main section of the machine from the collar (11). Look
into each nozzle for signs of debris or build-up

12

30

11

4125-0010

16

16

6

21

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Содержание GJ PF

Страница 1: ...4125 0000 Covering Standard machines First published 2015 07 100002784 EN2 2020 08 Original manual Instruction Manual Alfa Laval GJ PF ...

Страница 2: ......

Страница 3: ...9 4 1 Unpacking delivery 9 4 2 Installation 9 4 3 Recycling Information 12 5 Operation 13 5 1 Operation control 13 5 2 Trouble shooting 14 5 3 Cleaning solution leakage 17 5 4 Poor cleaning performance 19 5 5 Recommended cleaning 20 6 Maintenance 21 6 1 General maintenance 21 6 2 General dismantling set up 21 6 3 General dismantling 23 6 4 Inspection and service of components 26 6 5 Reassembly 33 ...

Страница 4: ... is in conformity with the following directive with amendments Machinery Directive 2006 42 EC DS EN ISO 12100 2010 The Pressure Directive 97 23 EC According to its own volume and the rated pressure range the product is regarded an Article 3 paragraph 3 Equipment The person authorised to compile the technical file is the signer of this document Global Product Quality Manager Hygienic Fluid Handling...

Страница 5: ...eaning machine 2 1 Important information WARNING Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the tank cleaning machine NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning Dangerous electrical voltage Caustic agents 5 ...

Страница 6: ...plate If the cleaning solution were hot corrosive or toxic a leak would present a serious hazard to any personnel In the immediate vicinity or to any exposed electrical equipment WARNING Any tank cleaning machine can develop a static electricity charge while in operation If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or explosion it is imperative to have...

Страница 7: ...void submerging the machine in the process vessel contents Any situations leading to partial or complete submersion of the unit should be verified with Alfa Laval beforehand Failure to comply with this restriction may void the warranty on the machine In order to handle the broadest possible range of applications the stainless steel Alfa Laval GJ PF is available with an extensive selection of nozzl...

Страница 8: ...mark of Alfa Laval Corporate AB Gamajet is a trademark or registered trademark of Alfa Laval The Alfa Laval GJ PF product has patent in the US US 6 123 271 US 6 561 199 Other products or company names mentioned herein may be the trademarks of their respective owners Any rights not expressly granted herein are reserved 3 4 Marking Alfa Laval tank cleaning machines are all marked to allow recognitio...

Страница 9: ... Always read the technical data thoroughly see section 7 Technical data Step 2 Assembly Every Alfa Laval GJ is operationally tested before shipment and is ready to run after unpacking No assembly is required prior to use The Alfa Laval GJ has been configured to meet the operating conditions at the Alfa Laval GJ not at the pump given to us e g pressure flow temperature cycle time chemical adders et...

Страница 10: ...J s position in the tank WARNING When attaching the Alfa Laval GJ PF onto the supply pipe ALWAYS apply the wrench to the inlet collar 11 at the top inlet of the unit Never use a wrench on stem 7 tee housing 8 or tee housing cap 15 to tighten the unit onto the pipe Doing so risks internally damaging the machine Refer to section 6 1 General maintenance 4125 0003 15 8 7 11 9 Step 5 Location inside ta...

Страница 11: ... with lower overall operating costs in these applications Furthermore to ensure that clogged filters or strainers are cleaned we recommend using automatic self cleaning models Step 9 Capacity of supply pump The Alfa Laval GJ PF can be used with either a centrifugal or positive displacement constant volume PD style pump In most cases if the PowerFlex is to be used with a centrifugal pump the PowerF...

Страница 12: ...rgy recovery Plastics should be recycled or burnt at a licensed waste incineration plant Metal straps should be sent for material recycling Maintenance All metal parts should be sent for material recycling Scrapping At end of use the equipment must be recycled according to relevant local regulations Beside the equipment itself any hazardous residues from the process liquid must be considered and d...

Страница 13: ...rmed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval GJ To ensure the longest possible life of the PowerFlex please verify the operating conditions and most importantly the machine s cycle time The cycle time can be measured by first picking a fixed point inside of a vessel as a reference and second timing how long it takes the same nozzle to pass bac...

Страница 14: ...of components Damaged planetary gearhead 14 section 6 4 Inspection and service of components Worn tee housing bearings 23 tee housing cups 8 2 section 6 4 Inspection and service of components Worn nozzle housing cup 9 3 nozzle housing bearing inner 25 nozzle housing bearing outer 24 section 6 4 Inspection and service of components No Does only tee housing 8 index Yes Worn tee housing bevel gear 17...

Страница 15: ...stator is too large the tee housing will not turn Look for restrictions in the fluid supply such as a clogged filter kinked hose or deposits in the piping Step 2 TIGHT CLEARANCES A recently overhauled Alfa Laval GJ Power Flex may fail to operate when first returned to service If the machine seems otherwise fine try running it with at least one nozzle removed The reduction in pressure and additiona...

Страница 16: ...r and the vanes of the rotor 32 1 Remove any material wound around the input shaft 33 1 32 1 33 1 12 30 11 4125 0005 3 4 In addition check for any debris caught in the nose of the tee housing 8 the nozzle housing 9 the nozzles 16 and the outlet holes of the stem 7 In order to check 7 the cap 6 must be removed and the gear train assembly pulled up and out of the stem 7 via the rotor 32 1 8 16 9 7 4...

Страница 17: ... lips are worn to a smooth surface or damaged lips or loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring and replace as required Worn housing cups Inspect the housing cups 8 2 and 9 3 for excessive wear grooved or scored Replace any that show distinct grooves 23 26 8 2 8 1 25 27 8 2 9 3 26 23 24 9 3 27 4125 0007 Worn collar O rings Sever...

Страница 18: ...akage through this point regardless due to the normal clutch operation but severe leakage is not ordinary Remove the tee housing as described in the general disassembly instructions and inspect the clutch O ring 29 for damage or wear The tee housing cap 15 stem base 22 stem screws 28 and lockwashers 38 cannot be installed into the tee housing 8 before the stem 29 7 4125 0046 8 7 4125 0009 15 28 22...

Страница 19: ...ing is necessary also check that the solution is at the proper temperature Plugged nozzles Unscrew the nozzles 16 and inspect for any debris Slow or no rotation of the housings This will result in partial or erratic washing coverage Refer to previous sections for more information Alfa Laval GJ configuration Determine if the deposit being cleaned requires greater jet impact or longer jet dwell time...

Страница 20: ...ng Step 1 Caustic danger Always handle lye and acid with great care Always use rubber gloves Always use protective goggles Step 2 Danger of burns Never touch the pump or the pipelines when sterilising 4125 0004 Step 3 Always rinse Always rinse well with clean water after using a cleaning agent NOTE Cleaning agents must be stored disposed of in accordance with current regulations directives 4125 00...

Страница 21: ...l depend on the severity of the application but a complete internal inspection at 100 hours of operation is recommended initially Step 1 STORAGE The Alfa Laval GJ should be washed out with clean water after each use to remove any foreign material or soft substances left in the machine that may harden during storage and cause the Alfa Laval GJ to seize or lock up A clean water rinse through the Alf...

Страница 22: ...d every 500 to 700 hours of operation depending on the severity of use 4125 0011 Step 4 TIPS All the bearings bushings seals and O rings are wear parts Ideally they should all be replaced as a group every 500 to 700 hours of operation depending on the severity of use If just one bearing or seal is worn or damaged replace both it and its mate not just the worn or damaged part Verify that the mating...

Страница 23: ...eral dismantling Step 1 Inlet collar 1 Loosen the collar set screw 30 with a 3 32 hex key minimum 2 turns 2 Remove the inlet collar 11 and stator 12 WARNING Hold or turn on stem DO NOT hold or turn on tee housing 8 or tee housing cap 15 Doing so will damage the gear train 12 30 11 4125 0013 7 4125 0014 8 15 9 23 ...

Страница 24: ... seal 27 included 3 Remove the inner nozzle housing seal 27 and inner bearing 25 NOTE Important to use a wide blade screw driver 27 24 10 1 4125 0015 Step 3 Cap and gear train 1 Using pliers or a bench vise on the flats of the cap 6 unthread it from the body 2 Pulling upward gently on the rotor 32 1 remove the gear train assembly from inside the stem 7 WARNING Hold or turn on stem 7 Do NOT hold or...

Страница 25: ...crews 28 with a 5 32 hex key and stem base 22 1 from the tee housing 8 NOTE The full gear train MUST be removed from the stem 7 BEFORE doing any of the steps on this page or it will be damaged 3 Remove the tee housing 8 by pulling it from the stem 7 The upper tee housing seal 26 and bearing 23 will pull off with the tee housing 4 Remove the lower 26 23 and bevel gear 17 1 15 1 22 1 38 28 8 4125 00...

Страница 26: ...nspect the collar stem O ring 41 for damage clipped or cut or deterioration compression set or hardening and replace if necessary 6 40 1 12 4125 0019 41 Planetary gear train assembly general disassembly and inspection Step 1 1 Pull the output shaft 13 from the planetary gearhead 2 Unscrew the rotor nut 4 with an 11 32 socket and remove it with the rotor lockwasher 3 from the gear train 3 Remove th...

Страница 27: ...e gearbox seals 35 did not come out of the gearbox 5 when the 21 1 and 20 1 were removed remove them at this time WARNING To reduce the likelihood of scratching any sealing surface use a pick made from brass Inspect the 35 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required 32 2 32 1 3 4 4125 0020 21 4 21 3 21 1 13...

Страница 28: ...not feel completely comfortable servicing 14 contact Alfa Laval immediately 1 Using a needle nose pliers carefully remove the internal components of the planetary gearhead 14 2 Examine the gears of the four different stages for any worn or broken teeth Also examine the main internal ring gear for bent or sharp teeth If any damage is found contact Alfa Laval GJ immediately 3 The gears of the bottom...

Страница 29: ... replace using a brass pick to remove the old components if necessary The 34 should be installed so its internal spring is up and visible 6 The pin 20 2 should be firmly pressed into the input shaft upper bearing housing 20 1 The carbide 20 3 in the 20 1 should protrude slightly In addition its running surfaces should be smooth flat and free of chips and cracks 20 1 33 1 33 3 35 33 2 42 34 2 20 2 ...

Страница 30: ...ng is acceptable but the 9 3 should be replaced if they are grooved in the seal contact area A good maintenance program will require replacing many 9 3 therefore it may be worthwhile to make or obtain press tools for pressing 9 3 out of 9 The press tools are available from Alfa Laval GJ cleaning systems Before installing new 9 3 clean the housing bores and remove any burrs resulting from 9 3 remov...

Страница 31: ...s required 5 Inspect the tee housing cap O ring 1 for compression set or deterioration 6 Inspect the tee housing bevel gear 17 1 for worn damaged or sharp pointed teeth 7 Ensure that the pin 17 2 is pressed firmly into 17 1 8 Replace if needed 9 Clean any deposits from 8 2 and examine for excessive wear Light scoring is acceptable but the cups should be replaced if they are grooved in the seal con...

Страница 32: ...e present in the stem 7 1 if the machine is a clutch machine In order to make the machine a pin driven machine 7 2 must be pressed into the hole in 7 1 The clutch o ring 29 remains in place even if the machine is pin drive WARNING Once a machine is converted to pin drive the nozzle housing 9 will no longer rotate freely by hand Forcing 9 to rotate WILL damage the machine To convert a pin machine b...

Страница 33: ...f threads and ease any future disassembly To ease installation of all O rings they should be lubricated prior to reassembly Lithium based grease is acceptable for Viton O rings however silicone based lubricant must be used for EP O rings Do NOT grease the clutch O ring 29 Refer to the illustrations in Appendix C for clarification during reassembly Gear train Step 1 1 Insert the gearbox screws 31 t...

Страница 34: ... the gearhead screws 39 back into the gearhead using a 2 Phillips screwdriver Make hand tight 39 5 4125 0031 Step 3 1 Install the gearbox seals 35 into gearbox The seal s internal spring should be face out and be visible 2 Install the upper 20 1 and lower bearing housings 21 1 into the proper ends of the gearbox by using equal pressure around parts They will snap into place 21 1 20 1 35 5 35 4125 ...

Страница 35: ...s list and service kits section Step 4 1 Place the rotor 32 1 over the end of the input shaft 33 1 2 Install the rotor lockwasher 3 and rotor nut 4 using an 11 32 socket Hold the 32 1 stationary with a pair of pliers while tightening the 4 20 3 32 1 3 4 4125 0033 33 1 13 35 ...

Страница 36: ... and fully seated 4 Install the second 26 spring side down over the 7 1 26 8 1 26 23 17 1 7 1 4125 0034 Step 2 Tip 1 Place the second tee housing bearing 23 into stem base 22 1 aligning its hole with the bearing locating pin 22 2 2 Invert the 8 1 7 1 assembly and place it over 23 22 1 assembly This technique ensures correct alignment of 23 and 22 2 3 Apply pressure to 22 1 to drive it 23 and 26 in...

Страница 37: ...E This is a left hand thread 15 1 38 28 8 1 4125 0036 7 1 Gear train installation Step 1 Item 1 Item 2 3 1 Insert the gear train from 6 4 Inspection and service of components into the body assembly 2 Rotate the tee housing 8 1 until the output shaft 13 falls into the slot of the tee housing cap 15 3 Thread the cap 6 into the body assembly Be sure to use the flats provided on the 6 Tighten WARNING ...

Страница 38: ...o the annular space between the 8 1 and nozzle housing cup 9 3 7 Using a screwdriver screw the nose plate 10 1 into the 8 1 16 1 16 3 9 16 3 16 1 8 1 8 3 25 27 10 2 9 3 27 24 10 1 4125 0038 16 2 16 2 NOTE Note that failure to align the pin 8 3 into the inner tee housing bearing 25 and the outer pin 10 2 pin into the outer tee housing bearing 24 will crack the bearing and render it unusable NOTE Im...

Страница 39: ...Full pattern The above drawings show the cleaning pattern achieved on a cylindrical horizontal vessel The difference between the first cycle and the full pattern represents the number of additional cycles available to increase the density of the cleaning Certificate 2 1 material certificate PHYSICAL DATA Materials 316L PPS PTFE EPDM FKM and FFKM available Temperature Max working temperature 90 C 1...

Страница 40: ...5 4 17 4 19 4 15 25 35 45 55 65 75 85 15 45 75 105 135 165 195 225 255 285 PSI bar A 6 4 mm 1 4in B 7 9 mm 5 16in C 9 5 mm 3 8in Inlet pressure Impact throw length m ft Nozzle 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 5 10 15 20 25 30 35 40 45 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 30 60 90 120 150 180 210 240 A B C D 4125 0041 E PSI bar A 6 4 mm 1 4in B 7 9 mm 5 16in C 9 5 mm 3 8in D ...

Страница 41: ...llation operation and maintenance Inform personnel about the technical data Cleaning time rpm min Stator 4 5 7 5 10 5 13 5 16 5 19 5 22 5 2 6 10 14 18 22 26 30 34 38 42 46 20 30 40 50 60 70 80 90 100 110 1 3 2 6 10 30 4125 0042 A B C D E USgpm m3h A LP B STD C MV D LM E HV 41 ...

Страница 42: ...d maintenance Inform personnel about the technical data 7 3 Dimensions Dimensions 4125 0043 B A C D E F G H I Dimensions A B C D E F G H I mm 272 204 175 44 94 176 202 98 129 in 10 70 8 01 6 88 1 73 3 69 6 90 7 95 3 83 5 05 NOTE 1 1 1 2 FNPT 2 camlock or 1 1 2 BSP 2 camlock option shown above 42 ...

Страница 43: ... 43 ...

Страница 44: ...26 8 2 8 3 8 2 38 8 1 26 25 27 36 37 20 3 16 3 23 19 9 1 16 1 17 1 18 29 9 3 7 2 7 3 9 2 10 2 7 1 17 2 9 3 16 3 27 24 16 1 10 1 39 33 3 33 1 5 30 31 14 33 2 42 34 2 32 2 35 20 2 20 1 11 40 32 1 3 4 41 6 1 12 4125 0001 21 4 21 3 21 2 21 1 35 13 16 2 16 2 16 1 16 2 16 3 16 3 16 1 16 2 9 1 44 ...

Страница 45: ...nput shaft carbide bearing upper housing 21 1 Gearhead upper bearing housing assembly 21 1 1 Gearhead upper bearing housing 21 2 1 Output shaft upper carbide bearing 21 3 1 Output shaft upper seal 21 4 1 Output shaft retaining ring 22 1 Stem base assembly 22 1 1 Stem base 22 2 1 Bearing locating pin 22 3 1 Output shaft lower carbide bearing 23 2 Tee housing bearing 24 1 Nozzle housing bearing oute...

Страница 46: ...is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corporate AB Alfa Lava...

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